Enhanced protective layering process to accommodate circuit board heat dissipation

ABSTRACT

A polymer layering process that encapsulates and protects electronics components with complex and imprecise geometries. The protective layering process provides a combination of a flexible mold and/or a rigid mold that apply close-forming, encapsulating the polymer layers to the electronic components and precision assemblies. Polymer layer protective jackets are shaped to as-populated circuit boards and assemblies, providing tightly fit barriers with fine resolution accommodating imprecise geometries. The protective jackets can be formed in rigid, semi-rigid, or highly flexible polymer films, to protect the circuitry from the elements, CTE mismatches, shock and vibration loads and extreme g-forces, and external electromagnetic emissions. By altering the protect layer configuration, the protective layer can accommodate populated circuit board assembly with high heat generation component(s).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Continuation-in-part of U.S. patent application Ser. No. 14/249,540 filed on Apr. 10, 2014 which is itself a continuation-in-part of U.S. patent application Ser. No. 13/682,980 filed Nov. 21, 2012, which claims the benefit under 35 USC § 119(e) of U.S. provisional patent application 61/563,939, filed on Nov. 28, 2011, both of which are incorporated by reference in their entirety.

GOVERNMENTAL INTEREST

The invention described herein may be manufactured and used by, or for the Government of the United States for governmental purposes without the payment of any royalties thereon.

FIELD OF THE INVENTION

The present invention relates in general to the field of circuit board manufacturing. More specifically, this invention relates to an improved, protective, thin film layering process that protects electronic components with complex and imprecise geometries. The protective layering process provides a combination of a flexible mold and a rigid mold, or another means to produce the same that apply close-forming, encapsulating polymer or other layers to the electronic components.

BACKGROUND OF THE INVENTION

Conformal coatings are widely used in both the military and industrial electronics applications, for protecting circuit board assemblies from moisture, dust, chemicals, and temperature extremes, to prevent damage or failure of the electronic components. While the use of conformal coatings offers several advantages compared to uncoated circuit board assemblies, their application constitutes a “wet-process” which requires the use of hazardous chemicals that must be applied by spraying, brushing, or dipping, followed by drying and/or curing processes.

In addition, it would be difficult to control the conformal coating thickness as well as the formation of pin-holes. With the exception of parylene, which must be applied by expensive vacuum-deposition equipment and which does not lend itself to high-volume production, most organic conformal coatings are readily penetrated by water molecules.

For a conformal coating to be effective, ionizable contaminants, such as salts, must be prevented from reaching the circuit nodes where they can combine with water to form microscopically thin electrolyte layers that can be both corrosive and electrically conductive. Also, for the conformal coatings to adhere properly to the circuit board assemblies, thereby minimizing peeling, de-wetting, and the propensity to form pin-holes, all surface contamination must be removed prior to the application of the conformal coating, using another “wet-process” such as a vapor degreasing or semi-aqueous washing in a special equipment. Special shielding and masking measures must also be taken while applying the conformal coatings to prevent it from contaminating connectors, sensitive components and the circuit board assemblies.

The application of a close-fitting, thin-layer of polymer, or another material in flat-sheet form, over the circuit board assembly and its electronic components, either by a vacuum or pressure molding, or by other suitable processes, would offer superior protection from moisture, dust, chemicals, and temperature extremes compared to conformal coatings. A thin polymer layer, or multiple thin layers, could be selected to provide various additional attributes, such as, improved heat dissipation, ESD and EMI protection and control, and protection from handling and in-use shocks.

Thin polymer layers could be added to the circuit board assemblies for use in non-potted as well as potted applications. In potted applications, the polymer layers would offer additional benefits such as forming a barrier to prevent the potting material from seeping into areas around and underneath sensitive components. After being cured, potting materials could cause high stresses, such as a residual stress and a thermal expansion stress, during temperature cycling, due to the coefficient of thermal expansion mismatches and also due to contraction and expansion of the potting material itself.

More specifically, potting materials are being used with increasing frequency, in both commercial and military applications, to encapsulate the electronic components and circuit board assemblies of electronic systems. The use of potting materials allows for a simpler support-structure (while also enabling a smaller over-all system design) as well as enhanced structural support for the electronic components and circuit board assemblies against shock and vibration.

A major disadvantage with encapsulants or potting materials however, is the fact that they are permanent solid bodies that prevent any access or servicing of the components they encapsulate. Potting materials are almost always thermoset materials that harden once and cannot not be re-softened or reused

In numerous military munition designs, where the electronic components must survive the extremely high g-forces experienced during gun-launch, the potted electronics are inactive until the munition is used. Until this time the munition may have been in storage without environmental (temperature and humidity) controls for up to 20 years.

In contrast, the electronics for most commercial applications tend to be active for most of their lifetime where the operating environment is more stable and predictable. Without external temperature controls, or the fairly constant temperature environment that active electronics create for themselves, inactive electronic components experience continuously varying physical stresses which are created due to their intimate contact with the potting material and the different rates of expansion and contraction that each produces with changes in temperature. If the changes in temperature are severe enough, or repeated a sufficient number of times, the physical stresses induced on the inactive electronic components can be severe. The resultant loads or stresses can be high enough to fracture the ceramic lids of hollow-cavity devices, or other types of electronic components, and may also lift components completely off of their circuit boards.

In addition, during the potting process, the potting material may seep into the open spaces between the leads of the chips and also underneath the chip packaging. The potting material that has seeped into these areas will create residual stresses in the solder joints and also against the packaging bottom surface after the potting material has solidified during the curing process.

Currently, the following failures have been observed for potted electronics during either the temperature-cycling qualification process or the life test (temperature-cycling and gun-launch) of a sub-system of the fielded-artillery system:

-   -   1. Solder joints failed during the temperature-cycling process.     -   2. Solder joints failed during the life test.     -   3. Lids and lid-seals cracked on MEMS (e.g.         MEMS—Micro-Electro-Mechanical Systems) open-cavity devices         during the temperature-cycling process and also during the life         test.     -   4. Tiny electronic devices pulled off from their circuit boards         during the temperature-cycling process.

The application of a barrier, such as a thin layer of polymer (or other material), over the electronic components prior to the addition of the potting material, is believed necessary to help mitigate the above failures. The polymer layer can be applied by various processes such as heat, vacuum, vacuum plug assist, radio frequency forming or a combination of processes, or a combination of the above.

For failures resulting from the solder joints failure and components being pulled off their circuit board assemblies during temperature cycling, the polymer layer would prevent the potting material from intruding between the chip-leads and also under the chips, and thus help prevent the push and pull stresses that the potting material would produce as it expands and contracts with increasing/decreasing temperatures.

For failure resulting from both lids and lid-seals being cracked on hollow-cavity devices, the polymer layer would provide: 1) a low-adhesion boundary between the potting material and the lid surfaces thereby mitigating the high shear-stresses that would develop as the potting material expands and contracts due to ambient temperature fluctuation, and 2) a compliant layer that would minimize the high-compression stresses that the potting material develops when it expands, due to increasing temperatures, and high-tension stresses that the potting material develops when it shrinks, due to decreasing temperatures, against the lids of these devices.

What is therefore needed is a process of forming and emplacing the thin polymer, or other formable composite, layers so as to precisely conform to the imprecise geometries of the electronic components on the circuit board assemblies, despite the imprecise geometries of these components due to their geometrical tolerance, placement tolerance as well as the manufacturing and assembly variances of the circuit board assemblies. It would also be substantially advantageous that the polymer layers be sufficiently strong to provide the structural support of the potting to the circuit board assemblies during high-g force events. It would further be desirable to have the thin polymer layers be sufficiently flexible to allow for differentials in coefficients of thermal expansion between the circuit board assemblies and the potting material.

Certain publications, such as U.S. Pat. No. 5,318,855, propose a method to vacuum form a polymer film over the circuit board assemblies to provide electrical and environmental protection. However, the proposed method does not seem to allow the polymer layer to precisely conform to the electronic components.

U.S. Pat. Nos. 4,959,752 and 4,768,286 suggest vacuum forming polymer layers over a circuit board assembly to closely conform to the geometry of the circuit board assembly prior to the application of the potting material. However, these layers must be thin enough to permit vacuum forming over the circuit board assemblies, and are therefore too thin to provide sufficient structural support or to provide sufficient boundary to differential thermal expansion.

Another process of forming multiple layer films into packages to protect printed circuit boards is described in U.S. Pat. No. 7,161,092. This patent generally describes a method of forming a plurality of layers to cover the approximate shape of a printed circuit board assembly as opposed to mounting the electronic components in a container or enclosure. This method describes the bonding of at least three layers (i.e., insulating, conductive, and abrasion protection) into a conformal film that can be stamped or pressed, and then adhered to the electronic component assemblies, which may require breather valves. The surface tension of the individual layers usually provides an approximate fit, that is a fit with substantial radii or a loose fit encapsulating technique.

What is therefore needed is a process of forming the layers without the need for bonding individual layers together, and that produces a very tight fit between the polymer layers and the circuit board assembly. In addition, desirable process would not require adhesives or melting operations to join the layers to the circuit board assembly, and would provide an exacting polymer layer fit that facilitates snapping of the polymer layer to the assembly it is designed to protect. Such a desirable process would provide a polymer layer that follows the contours (or profiles) of all the electronic components on the circuit board assembly and would allow for variances in dimensional tolerances, placement and assembly. Prior to the advent of the present invention, the need for such a protective layering process has heretofore remained unsatisfied.

SUMMARY OF THE INVENTION

The present invention satisfies this need, and describes an improved protective layering process that protects electronics components with complex and imprecise geometries. The protective layering process uses a combination of a flexible mold and/or a rigid mold that apply close-forming, encapsulating polymer layers (or other composite layers created from other formable materials) to the electronic components.

The imprecise geometries are due to the normal electronic component geometrical tolerances as well as position-variations inherent in the manufacturing processes of the circuit board assemblies. It is an objective of the present invention to provide molding tools and forming methodologies that apply equal pressure, which will make the protective layers tightly fit to the electronic components of the circuit board assemblies, even perpendicular to the direction of molding. The soft durometer of the flexible mold face will flow or deform around individual components, applying force on sides of components in addition to the projected or top surfaces of components. This dual-material mold design is ideally suited to form polymer layers or other formable composite over electronic devices with varying tolerances.

To this end, the present invention includes a method for encapsulating a circuit board assembly for enhanced survivability in harsh and extreme environments with a thin polymer layer (or other composited layers created from other formable materials) tightly fit to the possible imprecise, as-built geometries of a populated, circuit board assembly. By precision scanning a circuit board assembly, and using the derived data, a male and/or a female mold can be created which is a substantially exact representation of the geometries of a completed circuit board assembly.

The data may be adjusted to scale the pattern, and therefore the associated mold, to allow for layer thicknesses, to form multiple successively larger layers, which may include thermally conductive, electromagnetic shielding layers, layers for impact protection, environmental protection, which may be placed on top of the first layer, to account for associated mold shrinkage, production polymer layer (or other formable composite layers) shrinkage, or for other reasons.

The populated circuit board may have at least one component, of a component type, wherein said component type is manufactured to a set of dimensional tolerances. These dimensional tolerances may be ascertained by consulting the data sheet, technical data package, or other appropriate reference. Once the populated circuit board has been scanned, and the surface data file has been obtained, the surface data file may be modified to allow for these dimensional tolerances. Such modifications may include, but are not limited to, modifying the surface file's representation of the scanned component into a representation of the component type, with dimensions set at the maximum extent of their respective tolerances.

The populated circuit board may have components with surfaces which are substantially vertical from the circuit board. That is to say the surface is approximately normal to the surface of the circuit board plane. The surface data file would also have a corresponding feature which is oriented substantially vertically, or at a normal orientation, from the data file's representation of the circuit board. The data file may be adjusted to add a draft angle to such a substantially vertical surface feature, where such an angle will result in the layer being slightly offset from the vertical surface of the component at the base of the component, and is closer to, or adjacent to the component as the feature nears the top of the component.

The data may be further adjusted to remove certain circuit board features which are in the form of small concavities, present on the circuit board and thus present on the original point cloud data or surface model, but which may be removed from the model for producibility of the mold and layer without compromising the integrity or functionality of the layers. Examples of such modifications may include, but are not limited to, removing gap spacing under component bodies, and removing certain component features, such as chip lead valleys, undercuts on component bodies or small concavities on component bodies, which may include chamfers or steps on the edges of components, which are on the order of not more than 20 mils wide, removal of which may improve manufacturability without jeopardizing the integrity of the EMI shielding or thermal conductivity or heat removal.

Taller components can present challenges in the forming of a layer, because of the larger distances over which the layer material must be drawn. For this reason, it may be advantageous to create cutouts, in a given layer, around the periphery of taller components. A cover can be formed, which may be of the same material, or one of similar properties, as the given layer, or may be of another material suited to the application. Multiple layers may have also substantially identical cutouts with a single, combined-property cover being emplaced over a component. Joining procedures may be used such as the use of adhesives, solvent bonding, ultrasonic welding, or radio frequency sealing will ensure a tight seal between the circuit board assembly polymer layer and the smaller covers for the tall components. For instance, a given layer may be of a primarily EMI shielding polymer layer, while the cover over the given component may be fabricated of a material which has both EMI and thermally conductive properties.

EMI and heat dissipation are frequently, important design variables for creating reliable printed circuit boards (PCBs). Additional layers may be added which have material properties suited to shield against EMI or to dissipate heat from high heat source components. While some materials can perform both functions, it is frequently advantageous to have a separate, individually optimized layer for each function. For instance, an EMI shielding layer may be fabricated of a polymer with EMI filler or may be a polymer layer which is plated with an EMI shielding material such as Copper. Although the Copper plating would also be thermally conductive, a plated, deposited, or similar layer of Copper may be too thin to provide sufficient thermal conductivity under some situations. A single thicker layer of Copper or other metal, which provides both EMI shielding and thermal conductivity may be used, however, there may be design considerations or manufacturability constraints which might make such a thick layer of Copper undesirable. An alternative may be a flexible layer of highly thermally conductive material such as a highly thermally conductive thermal graphite sheet. This material has a higher thermal conductivity than Copper and may be used in the layering process described herein.

Thermal graphite sheets, however, might typically require a substantially high temperature to permanently form into a layer conforming to the circuit board features. For this reason, it may not be cost effective to form such a layer to conform to all the features of the circuit-board. Instead, a thermal graphite sheet could be fabricated with cutouts around the component sections. Pre-formed covers can be used to wrap around the tall components and joining procedures such as the use of adhesives, solvent bonding, ultrasonic welding, or radio frequency sealing will ensure a tight seal between the circuit board assembly polymer layer and the smaller covers for the tall components.

A thermally conductive polymer may be used as a thermally conductive layer, however, in some situations a high heat generation component may require greater heat dissipation than a thermally conductive polymer can provide. Fillers may be added to the polymer to enhance its heat dissipation properties, but this layer may still not be sufficient to properly dissipate heat from high heat source components by itself. A Copper heat dissipation layer is generally the most frequently used heat dissipation layer, and may be used with this layering method. Optimally, a thermally conductive layer should be in direct contact with the heat dissipation surface of the component to be managed.

A cutout may be made in the interface layer about the periphery of the surface of a component which requires thermal management. This allows a subsequent thermally conductive layer or thermally conductive cover to be in thermal contact with the surface of the component, either via direct contract, or with the use of a thermal paste. Advantageously, a separate thermally conductive cover allows said cover to rest more directly on a component surface, should there be a dimensional variation in the height of the component, since the position of the cover surface over the component surface is no longer fixed to the height of the scanned sample.

A cutout may be made in the interface layer, and also in an EMI protective layer, leaving the top surface of a heat critical component uncovered. A cap of Copper or other material which has good thermally conductivity and good electromagnetic shielding properties can be placed directly on top of the component. Again, an adhesive with good thermal conducting qualities may be used to fill the gap between the protective layer and the cap, and to ensure good thermal conductivity between the cap and the surrounding thermal dissipation layer.

The polymer layer may be heated and a vacuum may be drawn through the mold, pulling the heated layer into a substantially precise representation of the circuit board assembly. The mold may also be heated, which allows for better temperature control of the thin polymer layer as it is formed, as opposed to an unheated mold, or as opposed to forming the layer directly against the circuit board assembly.

This forming (or molding) process allows for a substantially precise layer or layers to be produced using a broad range of materials, including such materials that may not be formed directly against the circuit board assembly. Formed layers may be applied to the circuit board assembly by physical emplacement, with the aid of heat and/or air pressure, with a precisely formed rigid mold or with the aid of a conformal mold or by a combination of rigid and conformal molds.

The conformal mold may have a rigid backing or reinforcement layer (heated or unheated) and a soft, front layer which substantially matches the various geometries of the circuit board assembly. When pressure is applied and the soft, conformal mold comes in contact with polymer covered circuit board assembly components, and is forced to flow or deform around individual components, the mold applies force on the sides of components as well as to the projected or top surfaces of the electronic components. The result of compressing the conformal mold over the polymer layer and the circuit board assembly is a protective layer that is tightly fitted to all components.

This method of encapsulating the circuit board assembly is particularly advantageous to create a barrier layer between the circuit board assembly and the potting compound which may be applied on top of the thin layer. As stated earlier, the polymer layer is precisely formed to the imprecise, as-built geometries of the circuit board assembly.

The polymer layer may be fabricated to be both flexible enough to protect the circuit board assembly from damage caused by differentials in coefficients of thermal expansion, due to environment temperature fluctuations, between the circuit board assembly and the potting material, without any appreciable degradation in the structural support provided to the circuit board assembly by the potting materials during extreme, high-g force events.

The advantages of the present invention include but are not limited to:

-   -   Provide a barrier for all lead frames, chip carrier frames,         miniature electronic devices, wired devices and all solder         joints from direct contact with the potting material, which will         then reduce the stresses caused by the expansion, contraction,         and lifting-action caused by the potting material during changes         in temperature.     -   Provide a flexible stress-reducing medium between the electronic         components of the circuit board assembly and the potting         material during changes in temperature and also during high         shock/vibration events.     -   Eliminate the shear forces experienced by the electronic         components, due to adherence of the potting material, during         changes in temperature and also during high shock/vibration         events.     -   Create a barrier that prevents the potting material from flowing         between the electrical leads and also underneath the electronic         packaging/components, thereby preventing the potting material         from pushing/pulling the components off the circuit board during         changes in temperature.     -   Provide a moisture barrier between the electronic components and         the operating environment.     -   Provide EMI shielding both from nearby internal electronic         components and also from EMI sources external to the electronic         components.     -   Provide a low-adhesion interface between the electronic         components and the potting material that will allow for easier         dissection/serviceability of the circuit board assembly.     -   Provide a thermal dissipation medium for high-heat generating         electronic components.     -   Provide one or more of the following to the circuit board         assembly: chemical protection, corrosion protection,         contamination protection, salt spray protection, fungus         protection, dust protection.

These and other advantages and features of the present invention will be more readily understood from the following detailed description of preferred embodiments of the invention that is provided in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other features of the present invention and the manner of attaining them, will become apparent, and the invention itself will be best understood, by reference to the following description and the accompanying drawings, wherein:

FIG. 1 is a perspective view of an exemplary circuit board assembly to be protectively layered according to present invention;

FIG. 2 is a high level flow chart of a layering process, which includes a mold making phase and a polymer layer forming phase according to the present invention;

FIG. 3 is a more detailed flow chart of the mold making phase of the layering process of FIG. 2;

FIGS. 4 through 9 are illustrations of the various steps of the mold making phase of the layering process of FIG. 3;

FIG. 10 is a more detailed flow chart of the polymer layer forming phase of the layering process of FIG. 2, according to a first embodiment of the present invention;

FIGS. 11 through 14 are illustrations of the various steps of the polymer layer forming phase of the layering process of FIG. 10;

FIG. 15 is a more detailed flow chart of the polymer layer forming phase of the layering process of FIG. 2, according to a second embodiment of the present invention;

FIGS. 16 through 18 are illustrations of the various steps of the polymer layer forming phase of the layering process of FIG. 15;

FIG. 19 is a more detailed flow chart of the polymer layer forming phase of the layering process of FIG. 2, according to a third embodiment of the present invention;

FIGS. 20 through 23 are illustrations of the various steps of the polymer layer forming phase of the layering process of FIG. 19;

FIG. 24 is a more detailed flow chart of a conformal mold making phase of the layering process of FIG. 2;

FIGS. 25 through 30 are illustrations of the various steps of the conformal mold making phase of FIG. 24;

FIG. 31 shows the polymer layer forming phase of the layering process, using the conformal mold made using the mold making phase of FIGS. 24 through 30;

FIG. 32 is an illustration of another embodiment of the conformal mold of FIGS. 24 through 31; and

FIG. 33 is an illustration of still another embodiment of the conformal mold of FIGS. 24 through 31.

FIG. 34 is an exploded view of a populated circuit board with a layer which has its vertical surfaces adjusted with a draft angle.

FIG. 34a-d are illustrations of various circuit board and component features which may potentially be removed from the surface data file without compromising the functionality of the protective layer.

FIG. 35 is an exploded illustration of an example case with multiple layers, each with a different function, and each molded with an offset to allow room for the layer or layers beneath it.

FIG. 36a is an exploded illustration of an example case of a PCB with a first interface layer and a second layer which may be an EMI shielding layer.

FIG. 36b is an exploded illustration of another example similar to FIG. 36a , but where cutout has been made in the second layer, which may be an EMI shielding layer, and where a cap, which may be made of an EMI shielding material has been provided to cover the electrical component and provide a continuous EMI shield.

FIG. 36c is an exploded illustration of an example case with a first interface layer and also a thermally conductive layer, wherein a cutout in the interface layer allows close physical contact between the electrical component and the thermally conductive layer, which enhances thermal energy transfer between them.

FIG. 36d is an exploded illustration of an example case similar to FIG. 36c , but where a thermally conductive material has been added between the electrical component and the thermal interface layer to further enhance thermal energy transfer.

FIG. 36e is an exploded illustration of another example similar to FIG. 36c , but where cutout has been made in the interface layer and in the thermally conductive layer, and where a cap, which may be made of an thermally conductive material has been provided to cover the electrical component and to connect to the thermally conductive layer, and where the cutout in the interface layer allows close physical contact between the thermally conductive layer and the electrical component.

FIG. 36f is an exploded illustration of an example embodiment with 3 layers: an interface layer, an EMI shielding layer, and a thermally conductive layer. A cutout has been made in all 3 layers approximating the top of the electrical component and a single combined-properties cap is provided to cover the electrical component and to connect to both the EMI shielding layer and the thermally conductive layer.

FIG. 37 is an exploded illustration of an example embodiment where an interface layer is modified to accommodate thermal management caps and to provide a uniform surface for a thermal conductive layer.

FIG. 38 is top perspective view of an example case of an interface layer having cutouts to accommodate thermal management caps and to provide a uniform surface for a thermal conductive layer.

FIG. 39 is an exploded illustration of an example embodiment where a cover layer provides a uniform surface for a thermal conductive layer.

FIG. 40 is a top perspective view of an exploded layer assembly showing an interface layer and a cover layer.

FIG. 41 is top perspective view showing an assembled interface layer and cover layer.

Similar numerals refer to similar elements in the drawings. It should be understood that the sizes of the different components in the figures are not necessarily in exact proportion or to scale, and are shown for visual clarity and for the purpose of explanation.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

FIG. 1 illustrates an exemplary circuit board assembly 100 which is to be protectively layered according to present invention, in order to protect electronics components 101, 102, 103, 104 with complex and imprecise geometries, that are secured (e.g., soldered) to a circuit board 111. To this end, the present invention includes a protective layering process 200 that is generally illustrated in FIG. 2.

The process 200 generally comprises two phases: a mold making phase 300 (as further illustrated in FIGS. 3-9 and 24-30), and a polymer layer forming phase 1000 (1500 or 1900, as further illustrated in FIGS. 10-23 and 31-33). These phases 300 and 1000 (1500 and 1900) will now be described in greater detail.

FIG. 3 provides a more detailed flow chart of the mold making phase 300 of the layering process 200 of FIG. 2. An aspect of forming the polymer layers according to the present invention, for the circuit board assembly 100, is to provide polymer layers with a substantially exact fit to the circuit board assembly 100. To create a mold that duplicates the circuit board assembly 100 exactly, it is determined that a mold cast from a populated circuit board assembly 100 would be superior to a machined mold. A machined mold would need to have been made from a CAD file that might not include all the imperfections or imprecise geometries of the actual populated circuit board assembly 100. It is important that the process 200 would allow for the shrinkage in both the mold casting process (e.g., aluminum) and the thermoplastic forming phase 1000 (FIG. 10) of the actual polymer layers.

At step 305 of FIG. 3, and as further illustrated in FIG. 4, the main circuit board assembly 100 to be protected is separated from auxiliary boards and connections.

At step 310 and as further illustrated in FIG. 5, the circuit board assembly 100 is scanned. A point cloud file 500 is then created from the scanned image. A white light laser computer tomography device (CT scan) may be used to trace the intricate physical geometries of the circuit board assembly 100, and to record all its features in the electronic point cloud file 500. The point cloud scan file (geometric points) is converted into a data or surface file by grouping the points into surfaces which are also blended or stitched together to form a single computer aided design/CAD file.

At step 315, the data/surface file is enlarged to another surface file 600 (FIG. 6), in order to accommodate for shrinkages of pattern(s), mold(s) and the protective films that will be deposited at a later stage of the phase 1000 (FIG. 10). In an exemplary embodiment, the data/surface file 500 was enlarged (i.e., grown) by approximately 0.012″ in to accommodate for the shrinkage of the cast aluminum mold (approximately 0.009″ in) and also for the shrinkage of the plastic films (approximately 0.003″).

At step 320, the enlarged surface file 600 may be converted to a STEP or layer file to facilitate printing of the enlarged model by a SLA/stereo lithography machine or other rapid prototyping or model printing machines.

At step 325, a negative or cavity plaster mold 700 is created. FIG. 7 illustrates one such plaster mold 700. More specifically, in the exemplary embodiment, stereo lithography pattern was used to create the plaster mold 700. A core box, with sprue and runner, was added to the plaster negative mold 700 to enable positive metal casting using the plaster cavity mold. The plaster negative 700 was oven dried after it was cast.

At step 330, a positive male metal mold 800 is made from the plaster cavity mold 700. The male mold 800 is also referred to as a drape mold. FIG. 8 illustrates one such metal mold 800. In the present exemplary embodiment, molten aluminum was poured into the plaster negative mold 700 to make the aluminum positive mold 800. The aluminum positive mold 800 is wire brushed and cleaned.

At step 335, and as illustrated in FIG. 9, several holes, i.e., 910, 920, 930 are drilled in the aluminum positive mold 800 of FIG. 8, so the mold is capable of plastic forming. The holes 910, 920, 930 will enable vacuum suction of the polymer films that will be deposited according to phase 1000 of FIG. 10. In the exemplary embodiment, the aluminum mold 800 is wire drilled/electrical discharge machined (EDM) to provide the holes 910, 920, 930 for pulling a vacuum or vacuum forming of the thin polymer films.

One or more polymer layers can now be applied to the circuit board assembly 100 by forming the thin layers on a drape mold (also called a male mold) or a cavity mold (also called a female mold). The precise fit of the layers to the circuit board assembly 100 can be formed on metallic molds that are duplicate copies of the circuit board assembly 100. The accuracy of the mold is a result of the scanning and printing process described earlier, which provides a mold geometry that is more accurate than machining and which includes even the smallest of features and textures. Using a metallic mold enables precise control of heating and cooling that was not possible when using circuit board assemblies or printed wiring boards as forms or molding tools.

With reference to FIG. 10, it illustrates the polymer layer forming phase 1000 of the layering process 200 of FIG. 2, according to a first embodiment of the present invention. The phase 1000 summarizes the process of forming one or multiple polymer layers that are also referred to as protective jackets to the circuit board assembly 100 with vacuum.

The phase 1000 enables a manufacturer to furnish thin film, polymer layers for the supplied circuit board assembly 100 in a number of thermoplastic materials. The polymer layers act as a barrier for a variety of potting materials used to encapsulate the circuit board assembly 100, to fill undesirable voids, and to adapt to discrepancies in the geometries of the electronic components of the circuit board assembly 100.

At step 1005 of the polymer layer forming phase 1000 of FIG. 10, a thin thermoplastic sheet 1100 (FIG. 11) is clamped (or affixed) to a rigid frame of the forming machine (not shown). While the thermoplastic sheet 1100 is still affixed to the rigid frame, it is heated at step 1010 under quartz lamps, until it softens. The thermoplastic sheet 1100 will sag when heated providing a visual that the thermoplastic sheet 1100 is ready to be formed. The heating temperature of the thermoplastic sheet 1100 varies with the material used. As an example, surface temperatures may vary between approximately 200° F. and 240° F. The heating step 1010 may for example take between approximately 20 to 40 seconds.

At step 1015, the thermoplastic sheet 1100 is moved (or lowered) over the drape or male mold 900. A machine slide enables the precise placement of the thermoplastic sheet 1100 film over the mold 900. As further illustrated in FIG. 11, the heated and softened thermoplastic sheet 1100 is lowered over the mold 900 and pushed down past the mold 900, to ensure a tight fit to the geometries of the electronic components of the circuit board assembly 100, as replicated on the male mold 900.

At step 1020, vacuum pressure of, for example, approximately 31 lbs. gauge is applied through the vacuum holes 910, 920, 930, to pull the thermoplastic sheet 1100 further around all the intricate features of the electronic components of the circuit board assembly 100.

At step 1025, the thermoplastic sheet 1100 is allowed to cool on the mold 900 using fan-forced, room temperature air. The cooling step 1025 would take approximately 20 seconds. The frame of the molding machine containing the cooled, formed thermoplastic sheet (or envelope) 1200 (FIG. 12) is raised.

At step 1030, the thermoplastic envelope 1200 is released from the frame, and any excess material of the thermoplastic sheet 1100 trimmed.

At step 1035, the thermoplastic envelope 1200 is placed on the circuit board assembly 100 (FIG. 13), and secured thereto. The enveloped circuit board assembly 100 is shown in FIGS. 13 and 14 and is designated by the numeral 1300.

The polymer layer forming phase 1000 may be repeated to form multiple layers on the circuit board assembly 100. The polymer layer forming phase 1000 offers a method of applying thin polymer layers over the electronic components of circuit board assemblies, which fit accurately around all components. The thin polymer layer(s) will have uniform thickness and consistent quality across the entire part as required by the application.

With reference to FIG. 15, it illustrates a polymer layer forming phase 1500 of the layering process 200 of FIG. 2, according to a second embodiment of the present invention. The phase 1500 summarizes the process of forming one or multiple polymer layers that are also referred to as protective jackets to the circuit board assembly 100 with vacuum.

At step 1505, a thin thermoplastic sheet 1100 (FIG. 16) is clamped (or affixed) to a rigid frame of the forming machine (not shown). While the thermoplastic sheet 1100 is still affixed to the rigid frame, it is heated at step 1510 under quartz lamps, until it softens. As indicated earlier, the thermoplastic sheet 1100 will sag when heated, providing a visual that the thermoplastic sheet 1100 is ready to be formed. The heating temperature of the thermoplastic sheet 1100 varies with the material used. As an example, surface temperatures may vary between approximately 200° F. and 240° F. The heating step 1010 may for example take between approximately 20 to 40 seconds.

At step 1515, the thermoplastic sheet 1100 is moved (or lowered) over the drape or male mold 900. A machine slide enables the precise placement of the thermoplastic sheet 1100 film over the mold 900.

At step 1515, and as further illustrated in FIG. 16, the heated and softened thermoplastic sheet 1100 is lowered over the mold 900 and pushed down past the mold 900, to ensure a tight fit to the geometries of the electronic components of the circuit board assembly 100, as replicated on the male mold 900.

At step 1520, vacuum pressure of, for example, approximately 31 lbs. gauge is applied through the vacuum holes 910, 920, 930, to pull the thermoplastic sheet 1100 further around all the intricate features of the electronic components of the circuit board assembly 100. This step results in a preformed thermoplastic envelope (or layer) 1710 (FIG. 17).

At step 1525, a heated negative mold 1700 is pressed against the preformed thermoplastic envelope 1710 and the mold 900 to further increase resolution (fitment) including undercuts. The negative mold 1700 is then removed, and the thermoplastic envelope 1710 is allowed to cool on the mold 900 using fan-forced, room temperature air at step 1530. The cooling step 1525 would take approximately 20 seconds.

At step 1530, the thermoplastic envelope 1710 is released from the mold 900, and any excess material of the thermoplastic sheet 1710 trimmed.

At step 1535, the thermoplastic envelope 1710 is placed on the circuit board assembly 100 (FIG. 18), and secured thereto, by for example, a layer of adhesive that can be applied to either the thermoplastic envelope 1710 or the circuit board assembly 100 (or both). The enveloped circuit board assembly 100 is shown in FIG. 18 and is designated by the numeral 1800. The polymer layer forming phase 1000 may be repeated to form multiple layers on the circuit board assembly 100.

With reference to FIG. 19, it illustrates a polymer layer forming phase 1900 of the layering process 200 of FIG. 2, according to a third embodiment of the present invention. The phase 1900 summarizes the process of forming one or multiple polymer layers to the circuit board assembly 100 with pressure.

With further reference to FIGS. 20 through 23, the polymer layer forming phase 1900 provides an alternative method of forming a thermoplastic or polymer layer 1100 using a heated female tool or negative cavity mold 1700 that is oriented to face in the downward position, facing the polymer layer 1100. The negative mold 1700 includes heat or air channels that are switchable from pulling vacuum to applying air pressure.

Heated molds are sometimes oriented facing downward (also referred to as upside down). The main reason for this orientation is that the conveyor feed where the items, such as circuit board assemblies, can be dropped into nests and remain in their position under the effect of gravity. Once in the forming machine, the circuit board assembly 100 is raised up into the cavities for over-molding, dropped back down on the conveyor and the cycle is repeated. Most often the male or female molds are on a work surface facing upward as vacuum is normally mounted below the machine. In addition, molds lower on a surface and facing upward provide a line of sight into the mold so that the operators can monitor the complete process.

The topography of the negative mold 1700 includes cavities and small features 2000, 2010 (FIG. 20) that correspond to the geometries of the components of the positive mold 900 and the circuit board assembly 100. The phase 1900 can form polymer layers in a single operation, or it can be used as a secondary operation to press-fit polymer layers (formed by the other forming methods, such as methods 1000 or 1500) over existing circuit board assemblies or printed circuit boards.

One aspect of the polymer layer forming phase 1900 is to have layers of various thicknesses and polymer composition be superposed and fit tightly over the electronic components of the circuit board assembly 100. By forming the layers to the geometry of the electronics components, a barrier is created to separate the circuit board assembly 100 from potting materials. Potting materials are used to encapsulate the sensitive electronics and cast them into a solid body.

The polymer layer barriers prevent potting materials from flowing underneath small electronic chips or components where they can be lifted off the printed circuit boards due to thermal movement among the dissimilar materials. The polymer barrier layers further protect the electronic components during manufacturing, assembly, and further during the storage life and product use from potting liquids, moisture, contaminants, dust and corrosion.

At step 1905, the heated thermoplastic sheet 1100 is applied to the negative mold 1700 (FIG. 20). At step 1910, vacuum pressure is used to pull the heated thermoplastic sheet 1100 tightly into the cavities and small features 2000, 2010 of the negative mold 1700, in order to produce a preformed thermoplastic envelope 2100 (FIG. 21).

The heated thermoplastic sheet 1100 conforms very accurately to the shape, placement, and geometry of the electronic components. As a result, the present phase 1900 addresses problems associated with the underside and vertical surfaces of the thermoplastic sheet 1100 and how closely it covers each electronic component. In order to accurately form the underside and internal sides of the thermoplastic sheet 1100, a drape or male mold is used in addition to the female mold (also referred to as cavity mold or appearance mold). A female mold may be used if surfaces of the mold need to be machined to produce larger parts. Female tools are considered “steel safe” because sections of the mold may be removed to accommodate larger electronic components.

At step 1915, and while the preformed thermoplastic envelope 2100 is still positioned at least in part, within the negative mold 1700, the positive mold 900 (or alternatively the circuit board assembly 100), is then moved into the cavities 2000, 2010 of the negative mold 2100, in such a way as to sandwich the thermoplastic envelope 2100 there between. This step will ensure that the thermoplastic envelope 2100 completely encases the geometries of components that are being protected.

While the thermoplastic envelope 2100 is still warm, the positive mold 900 is clamped in place to the negative mold 1700. The air direction in the negative mold 1700 is then reversed to press the thermoplastic envelope 2100 tightly over the geometries of the clamped positive mold 900.

At step 1920, the thermoplastic envelope 2100 is then allowed to cool and to shrink over the components geometries of the positive mold 900 (that correspond to the electronics components of the circuit board assembly 100). The thermoplastic envelope 2100 is cooled to a specific temperature in order to hold its shape and to prevent distortion.

At step 1925, and as illustrated in FIG. 22, the thermoplastic envelope 2010 is released from the mold 900, and any excess material of the thermoplastic envelope 2010 is trimmed. As an example, the outside edges of the thermoplastic envelope 2100 are trimmed to the shape of the circuit board assembly 100. Temperature sensitive tape may be employed to bond the edges of the thermoplastic envelope 2100 shape to the flat of the circuit board 111 (FIG. 1).

Alternate methods of bonding the thermoplastic envelope 2100 barrier to the circuit board assembly 100 include adhesive bonding, solvent bonding to a texture, and ultrasonic welding to textures or three-dimensional features on the circuit board assembly 100. Also, an undercut, double bend or perimeter snap can be utilized to attach the thermoplastic envelope 2100 to the circuit board assembly 100 similarly to hardware blister packaging or food containers.

At step 1930, the thermoplastic envelope 2100 is placed on the circuit board assembly 100 (FIG. 23), and secured thereto, by for example, a layer of adhesive that can be applied to either the thermoplastic envelope 2100 or the circuit board assembly 100 (or both). The enveloped circuit board assembly 100 is shown in FIG. 23 and is designated by the numeral 2300. The polymer layer forming phase 1900 may be repeated to form multiple layers on the circuit board assembly 100.

The phase 1900 is also applicable to solve potential circuit board assembly electromagnetic interference (EMI) problems, and may include the following steps:

1) Application of an insulation layer to the components, section or assembly requiring protection. The layers will be tightly fit around components.

2) Application of an electrically conductive shielding product to the top of the first layer. These materials include metal foils, metalized fabrics or cloth, metal particle polymer composites, plated fiber composites, vacuum metalized layers, electroless plated layers, etc.

3) Solder or mechanically attach the shielding material to the ground features on the circuit board assembly 100.

In situations where the electronic devices of the circuit board assembly 100 have very high heat dissipation/generation, the following step will be added prior to the application of the electrically conductive shielding product to the top of the first layer:

Cut the non-conductive layers around the periphery of the hot electronic component, and remove the non-conductive cutout. Replace the removed non-conductive layers with high thermal conductive material or pad to transfer heat away from the electronic component.

FIG. 24 illustrates a conformal mold making phase of the layering process 200 of FIG. 2, which is referenced by the numeral 2400. According to this phase 2400, a conformal mold 2800 is fabricated with a flexible (soft or conformal) layer 2700 that is secured to a rigid layer (or backing) 2710 that enables the application of close-forming, encapsulating polymer layers (or layers) to the circuit board assembly 100 having complex and imprecise electronic component geometries. The imprecise geometries of the electronic components of the circuit board assembly 100 may be due to the normal electronic component geometrical tolerances as well as position-variations inherent in the circuit board assembly 100 manufacturing processes.

It is an objective of the conformal mold 2800 to provide a molding tool that applies equal pressure to the electronic components of the circuit board assembly 100, including surfaces that are perpendicular to the direction of forming (or molding). The soft (or flexible) durometer of the flexible (e.g., compliant) mold face will allow the polymer to flow or deform around individual electronic components, and the application of a force on the sides of the electronic components as well as to the projected or top surfaces of the electronic components. This dual-layer (soft-rigid) mold design is suited to form polymer layers over electronic devices with varying tolerances.

While soft presses are known to conform polymer layers to the circuit board assembly 100, as in U.S. Pat. No. 7,752,751, they have not been of substantially flat nature and have not been shaped to substantially match the shape of the circuit board assembly 100. Therefore, they do not apply pressure as uniformly to the polymer layer as the present invention.

The present invention includes creating the conformal or flexible face 2700 on a molding tool that will apply close-forming polymer layers on the circuit board assembly 100. The geometric variations of the circuit board assembly 100 include, for example: component-placement positioning variations; solder paste height variations; geometrical tolerances of the electronic components; and open-cavity devices (e.g., MEMs) seal thickness variations. With all these variations, the conformal mold 2800 of the present invention will provide consistent and accurate application of encapsulating polymer layers (or layers) over the individual electronic components.

It is an object of the phase 2400 to fabricate a conformal mold 2800 with a soft section 2700 whose shape is developed based on the combinations of the nominal dimensions of the electronic components of the circuit board assembly 100, the electronic components geometrical tolerances, and the electronic components placement variations. The conformal mold 2800 can be primarily constructed as a silicone or elastomer soft body which may be backed up by a rigid support plate 2710, or may be a shaped silicone or elastomer face on a rigid mold which follows the geometry of the circuit board assembly 100.

Referring now to FIG. 24, it illustrates the conformal dual-layer mold making phase of the layering process 300 of FIG. 2, which is also referred to as phase 2400 to distinguish this phase over the other mold making phases described herein.

At step 2405, and with further reference to FIG. 25, the actual, populated circuit board assembly 100 (or an exact replica thereof, i.e., the positive mold 900) is placed in a casing or fixture 2510 that provides for accurate positioning and orientation of the circuit board assembly 100.

At step 2410, and with further reference to FIG. 26, in order to create the dual-layer mold 2800, a pattern of the final circuit board assembly 100 topography is created by applying successive, patterned polymer layers 2600 to the circuit board assembly 100. The polymer layers 2600 are of appropriate thicknesses and flexibility so that they closely form to the topology of the electronic components. The successive layers 2600 can be applied, for example, with heat and vacuum from below (or a heated dual-layer mold), and air pressure from above the circuit board assembly 100. Soft pads may be used to apply pressure over electronic components of the circuit board assembly 100. The successive polymer layers 2600 account for the actual thermoplastic sheets or layers that will formed at the later stage of the manufacturing process.

At step 2415, and with further reference to FIG. 27, in order to prepare a cavity and shape 2750 for the soft layer 2700 of the mold 2800, the number of successive polymer layers 2600 needs to be determined. Layer count and layer thickness are dependent on several factors, among which are the following: the requirements of the final encapsulated circuit board assembly 100 including environmental, physical and mechanical considerations; and the desired thickness of the soft layer 2700 to provide a robust forming tool while satisfying the service life expectancy. In creating the soft layer 2700, the thickness of the polymer encapsulation layers 2600 needs to compensate for the electronic components dimensional tolerances. Designing and creating the conformal mold (or soft) face 2700 to accommodate for component tolerance requirements ensures a constant interface pressure between the soft layer face 2700 and the polymer layers 2600 despite the geometric complexities of the electronic components.

At step 2420, and with further reference to FIG. 28, the rigid reinforcement portion 2710 of the conformal mold 2800 is made using the fixture 2510 and the circuit board assembly 100 with the applied polymer layers 2600 and spacing 2750. The conformal or soft portion 2700 of the mold requires a high degree of details from the topography of the circuit board assembly 100, such as small surface mount devices, component leads, white-wires, etc. However, the rigid portion 2710 of the mold 2800 serves to strengthen the conformal face 2700.

As such, the rigid portion 2710 of the mold 2800 can be made from casting materials, usually thermoset resins with metal fillers, as the back or reinforcement is not expected to experience high stress or wear, nor excessively-high temperatures, while in use. The rigid portion 2710 of the mold 2800 may have features such as dovetails or keyways 3200 (FIG. 32) to mechanically engage the flexible material (soft layer) 2700 when poured, creating a mechanical bond between the two dissimilar materials. The casting is performed in such a way that it locates accurately with the fixture 2510 holding the circuit board assembly 100.

At step 2425, and with further reference to FIG. 29, the soft compliant portion 2700 of the conformal mold 2800 is formed by placing another actual circuit board assembly 100 or mold 900 into the fixture 2510, and by applying a very thin polymer layer 2900 as described earlier. This polymer layer 2900 is made as thin as possible to allow for the possibility that the electronic components sizes and positions on the circuit board assembly 100 may have ranged to their largest tolerances.

Next, a mold release is applied to the polymer layer 2900. In creating the soft mold face 2700, silicone (or another suitable elastomeric material with appropriate properties) is applied to the component-cavities 2750 (FIGS. 27, 28) and other surfaces that will face the circuit board assembly 100. During the pouring or injection of the flexible material for the soft mold face 2700, the silicone or equivalent material will flow into the locking features of the rigid mold backing 2710, bonding them as a single unit. Next, the combined mold 2800 is allowed to cure around the fixtured circuit board assembly 100. The height of the compliant mold 2800 relative to the circuit board assembly 100 must be controlled so that the flexible mold face thickness is maintained with regard to the circuit board assembly 100 and the electronic components thereon.

At step 2430, and with further reference to FIG. 30, once the flexible mold face material (soft layer 2700) has cured, the fixture (or molding tool) 2510 can be separated from the circuit board assembly 100. The compliant mold 2800, which includes both the soft layer 2700 and the rigid backing 2710, is now ready to be used to apply the encapsulation polymer layer(s) to the circuit board assemblies 100 with complex and imprecise geometries.

FIG. 31 illustrates the process of applying one or more polymer layers to the circuit board assembly 100. In this process, a circuit board assembly 100 from a product line with imprecise geometries is ready for applying a close-forming polymer layer (or layers) 1100 or 1710 to its surface. The conformal mold 2800 is used to apply pressure to the polymer layer 1100 or 1710, as described earlier in connection with processes 1000 (FIG. 10), 1500 (FIG. 15), and 1900 (FIG. 19). As illustrated by the arrows in dotted lines, in some instances, it might not be possible or advantageous to apply vacuum from underneath the circuit board assembly.

If the height of the electronic components exceeds formability of a selected polymer layer, the circuit board assembly 100 could optionally be encapsulated by a polymer layer with cutouts around the tall component sections. Pre-formed polymer covers can be used to wrap around the tall components and joining procedures such as adhesives, solvent bonding, ultrasonic welding, or radio frequency sealing will ensure a tight seal between the circuit board assembly 100 polymer layer and the smaller polymer covers for the tall components.

The soft conformal mold face (or layer) 2700 may be made of a single material construction or multiple layers of different materials.

The conformal mold 2800 provides the ability to form or process polymer layers to a great degree of accuracy, resolution, and tolerance. While the forming methods 1000, 1500, and 1900 use heat, vacuum, and/or pressure, the conformal mold 2800 uses mechanical forming around the intricate components. The soft or conformal face 2700 of the conformal mold 2800 has the ability to mechanically form or shape the thermoplastic layers in addition to the vacuum or air pressure forming. The soft face 2700 of the mold 2800 is soft enough to flow around the electronic components when closed against the opposite mold or pressed tightly onto the populated circuit board assembly 100. In this manner, the soft geometry of the compliant mold face 2700 pushes the polymer layer not only on the top surface of components, but it also applies pressure to the layer on the sides of components as the compliant mold face 2700 deforms to comply with the geometries of the electronic components.

In addition, the present three-dimensional mechanical forming produces layers with a significant fit to the unique topology of the numerous circuit board assemblies despite minor differences on the height, axial and position tolerance of soldered components.

FIG. 33 illustrates a compliant mold 3300 according to another embodiment of the present invention. The soft compliant layer 2700 is formed according to process 2400, as described earlier, and is shown enlarged relative to its actual size for the purpose of illustration. Conductive traces 3310 are formed within the soft compliant layer 2700 in order to facilitate the heating of the soft compliant layer 2700.

In this particular exemplary embodiment, the conductive traces 3310 include thermally conductive fillers 3320, connecting wires 3333, and embedded heating pads 3330. One or more externally accessible pads 3344 may also be added.

While it is highly desirable to cause the conformal mold 2800 to form polymer layers around the electronic components and complex geometries, the soft compliant face 2700 that has an internal heat source (heat sources, or conductive traces) 3310 can form the parts faster and with greater accuracy. Elastomers and silicones are thermally non-conductive allowing very little heat to pass through the material even in thin cross sections.

FIG. 34 illustrates a populated circuit board layer 111 with an electronic component 103, and a formed layer 3401, wherein feature 3403 of layer 3401 which correspond to substantially vertical surfaces 3402 of the electronic component 103 have been modified with a draft angle. In this case, to say that a surface is substantially vertical is to say that the surface is approximately normal to the surface of the circuit board plane. This modification to add the draft angle to the layer is accomplished by modifying the data file which has been produced by the scan of the populated circuit board. It may be advantageous to add such draft angles to facilitate placement of a layer over the populated circuit board, or to remove said layer, for instant in the event a rework of the circuit board must be carried out.

FIG. 34 a-d illustrates various circuit board component features which may potentially be removed from the surface data file without compromising the functionality of the protective layer. These features would be small concavities present on the circuit board and thus present on the original point cloud data or surface model, but which may be removed from the model for producibility of the mold and layer, without compromising the integrity or functionality of the layer.

FIG. 34a illustrates a modification to the surface data file to remove a space 3404 underneath a circuit board component 103 and also to remove chip lead valley 3405 from the surface data file. A scanned electronic component may have a space 3404 underneath, and this space may exist on a 3d scan. It may be advantageous to modify the data file 3407 to remove this empty space and instead have the component's representation in the data file extend all the way down to the circuit board surface. Including a feature to correspond to the space under a component would generally not be beneficial to include in a protective layer, and the retention of the space in the data file and subsequently produced layer may be a hindrance to placing the layer on the circuit board. Chip lead valleys 3405 may also be removed where a component has leads 3406 extending from the component edge, where said leads extend outwardly and towards the surface of the circuit board. These leads form hollows, known as chip lead valley, between them, hollows which may not have to be included in the layer for proper functionality. As such removing these chip lead valleys from the data file and subsequently fabricated layer, and instead having a uniform geometry 3408 bridging the chip leads, would save manufacturing expense.

FIG. 34b illustrates where an electronic component has a concavity which is a small groove in its surface. It may be advantageous, for manufacturability, to remove such concavities from the data file 3407 and instead have the component's representation in the data file include a continuous surface 3410 in place of the groove. This is because such a groove may not be beneficial to include in geometry of a protective layer, and its removal may save manufacturing expense. The maximum groove which may be removed is dependent on the design situation but generally removal of chamfers or steps on the order of not more than 20 mils wide of may improve manufacturability without jeopardizing the integrity of the EMI or thermal conductivity or heat removal.

FIG. 34c illustrates electrical components 103, 104 with small chamfers 3411 or steps 3412 about their edges between surfaces. It may be advantageous, for manufacturability, to remove such chamfers or steps from the data file 3407 and instead have the component's representation in the data file remove the chamfer or step such that the data file's representation of the surfaces meet at an edge 3413 instead of including the intervening chamfer or step. This is because such chamfer or step may not be beneficial to include in geometry of a protective layer, and its removal may save manufacturing expense. The maximum size chamfer or step which may be removed is depends on the design situation but generally removal of chamfers or steps on the order of not more than 20 mils wide of may improve manufacturability without jeopardizing the integrity of the EMI or thermal conductivity or heat removal.

FIG. 34d illustrates an electrical component with a hollow undercut 3414 which is setback from an overhanging portion of the electrical component. It may be advantageous to modify the data file 3407 to remove this empty space and instead have the component's representation in the data file extend 3416 all the way down to the circuit board surface. Such an undercut would generally not be beneficial to include in a protective layer, and its retention in the data file and subsequently produced layer may be a hindrance to placing the layer on the circuit board.

FIG. 35 is an exploded illustration of an example embodiment of a populated circuit board 111 with at least one electronic component 103, and with multiple layers, each which would be fabricated of a different material to serve a particular function, and each would be molded with an offset to allow room for the layer or layers beneath it. The arrangement of layers can be tailored to the application.

It is recommended that the layer which is in contact with the circuit board 111, i.e. the bottom-most layer, be an interface layer 3501 that is both electrically insulative and structurally flexible, such as an elastomer or other very soft material preferably with a tensile strength of 1000 psi or lower. The electrical insulation is to prevent unwanted electrical connection; including unwanted connections both between the circuit-board layout paths, different circuit-board component's, different leads of a given component, and also between those items and a subsequent, electrically conductive layer, as this would likely result in a circuit-board malfunction. The Interface layer may also advantageously provide for additional compensation for component dimensional tolerance variations and component positional variations due to assembly process. The thickness of the interface layer 3501 may depend on the dimensional stability of the component tolerance and the manufacturing capability, but should typically be at minimum of 5 mils.

Each successive layer may be properly sized by determining the thickness of the lower layer or layers and taking into consideration manufacturing tolerance of each lower layer, and then creating a mold with an offset which accommodates said layer(s). Additional layers may include, but are not limited to, an electromagnetic interference (EMI) shielding layer 3502, a thermally conductive thermal management layer 3503, a high magnetic permeability material layer 3504 could be formed from a thin mu-metal sheet to shield against low-frequency magnetic fields, a protective structural support layer 3505, or other layers 3506. Other layers 3506 may be formed of materials such as, but not limited to polymer cover surface coating/plating or conductive painting (including but not limited to: copper, aluminum, silver), enhanced polymer with fillers (conductive hybrid composites) including but not limited to metal fiber/whisker reinforced composites, nonmetallic fiber/whisker reinforced composites, a matrix of conductive nano-composites—formed conductive network, graphite, nickel, carbon black, carbon-nanotube or other conductive filler.

FIG. 36a is an exploded illustration of an example embodiment of a populated circuit board 111 with at least one electronic component 103, and a first layer which may be an interface layer 350 and a second layer which may be, but is not limited to, an EMI shielding layer 3502. The interface layer may be formed using a mold derived from a scan of a circuit board. The second layer may be formed using the scan data, but with an offset included to account for the thickness of the first layer.

An EMI shielding layer may be produced using the technique described herein and may be fabricated of a polymer with an EMI shielding additive, or may be a polymer coated or plated with an EMI shielding material, such as Copper, Nickel, Tin, Gold, Chrome or conductive point. It may be advantageous, in some applications, to use a material with a EMI shielding coating, because materials with fillers may behave unexpectedly after being formed, or after any heating step in the manufacturing process. As used here, polymer layer may be a thermally formed polymer layer, an injection molded plastic layer, or 3d printed polymer layer. An EMI shielding layer could also potentially be made from a thin sheet of metal, e.g. Copper or Aluminum, or other metal which would produce an EMI shielding effect, but such a layer of metal, formed by itself, would need to be much thicker, due to forming considerations, than what would should be required for EMI shielding.

FIG. 36b is an exploded illustration of an alternate embodiment where a cutout 3601 has been made in the EMI shielding layer 3502, which cutout corresponds to the footprint of an electronic component 103. An EMI shielding cap 3602 may be formed, corresponding to the shape of the electronic component, and may be of the same material as the layer 3502 in which the cutout 3601 was made, or may be of a material with similar EMI shielding properties. This technique may be beneficial if an electrical component is taller, and the EMI shielding layer 3502 is of such a material that forming or drawing the EMI shielding layer 3502 material over said component height may present manufacturing challenges, such as tearing.

After the layers and EMI shielding cap 3602 have been put in place, joining procedures may be used such as the use of adhesives, solvent bonding, ultrasonic welding, or radio frequency sealing, along the border 3601 where the EMI shielding layer and the EMI shielding cap, meet, will ensure a tight seal between the circuit board assembly polymer layer and the cover for the components. In this embodiment, while there is a cutout in the EMI shielding layer 3502, to accept the EMI shielding cap 3602, there is no cutout in the interface layer 3501 corresponding to the electrical component 103. This is to allow the interface layer to continue to provide electrical insulation and the protective benefits of its elastomeric properties, over the electrical component, and also since an elastomeric material, of which the interface layer 3501 may be constructed, would be easier to form over taller components.

FIG. 36c is an exploded illustration of an embodiment wherein a second layer is a thermal management layer 3503 of a material with high thermal conductivity. In order to effectively remove heat from an electrical component 103, it is generally advantageous to have good thermal energy transfer between the electrical component 103 and the thermal management layer 3503. This may be accomplished, in this case, by having the thermal management layer 3503 in direct physical contact with the electrical component 103, or with an intervening layer of thermally conductive material, such as thermally conductive paste. In this case, it may be advantageous to create a cutout 3603 in the interface layer corresponding to the top of the electrical component 103 which is to be thermally managed, to allow good transfer of thermal energy between the thermal management layer and the component 103. The electrically insulative interface layer 3501 may be omitted from the top of the component, where the top of the component is not electrically conductive.

FIG. 36d is an exploded illustration of an embodiment with a first interface layer 3601 which has a cutout 3603 approximating the top of an electrical component 103 which requires thermal management. A subsequent thermal management layer 3503 is also included. In this embodiment, thermally conductive material 3604, such as thermal paste has been included to improve the transfer of thermal energy between the electrical component 103 and the thermally conductive layer 3503.

FIG. 36e is an exploded illustration of an embodiment with a first interface layer 3601 which has a cutout 3603 approximating the top of an electrical component 103 which requires thermal management. A subsequent thermal management layer 3503 is also included. There is also a thermal management layer cutout 3605 approximating the top of the component 103.

A thermal shielding cap 3606 may be formed, corresponding to the shape of the electronic component, and may be of the same material as the layer 3503 in which the cutout 3605 was made, or may be of a material with similar thermally conductive properties. This technique may be beneficial if an electrical component is taller and the thermal management layer is of such a material that forming or drawing the thermal management 3503 layer material over said component height may present manufacturing challenges, such as tearing. The cutout/cap method may also be advantageous for a thermal management layer 3503 in particular, because of the importance of good physical contact between a thermal management layer 3503 and an electrical component 103 to be thermally managed. This is because the thermal management cap 3606 may be placed directly on top of the electrical component 103 before the thermal management cap 3606 is sealed to the thermal management layer 3503, which would mitigate any minute gaps between them that may have existed as a result of tolerances in the height of the electrical component 103.

After the layers and thermally conductive cap 3606 have been put in place, joining procedures may be used such as the use of an adhesive with good thermal conducting qualities, along the border 3605 where the thermally conductive layer 3503 and the thermally conductive cap 3606, meet, will ensure good transfer of thermal energy between the thermally conductive layer 3503 and the thermally conductive cap 3606.

FIG. 36f is an exploded illustration of an embodiment with a first interface layer 3501, a second layer which may be an EMI shielding layer 3502, and a third layer which may be a thermal management layer 3503. In this embodiment all 3 layers have a cutouts approximating the top of the electrical component 103 and a single combined property cap 3608 has been formed which has both EMI shielding and thermally conductive properties and which may be joined to both the EMI shielding layer 3501 and the thermal management layer 3505 at the edges of their respective cutouts 3601, 3605.

In certain embodiments employing a thermal dissipation layer for thermal management, it may be advantageous to provide a preceding layer with a surface having a uniform height for more effective heat transfer. Providing a surface with uniform height allows for certain materials and methods to be used which may be more effective at conducting heat from the circuit board. For example, with a uniform height, a flat sheet of graphite, a vapor chamber or a heat sink may be used to transfer heat from the electric components. However, this is not possible using the systems and methods described above due to non-uniform height of electrical components and associated thermal management caps. Accordingly, one approach to provide a uniform surface height is to manipulate an existing layer to provide a uniform height. A second approach to provide a uniform surface height involves the addition of a cover layer preceding the thermal management layer.

FIG. 37 is an exploded illustration of an example embodiment where an interface layer is modified to accommodate thermal management caps and to provide a uniform surface for a thermal management layer. A populated circuit board 111 with at least one electronic component 103 is covered by at least one protective layer 3502 and a thermal management layer 3503. In the embodiment shown, in addition to the thermal management layer 3503, the populated circuit board is covered by a first layer which may be an interface layer 3501 and a second layer which may be, but is not limited to, an EMI shielding layer 3502.

In an embodiment, the interface layer 3501 is both electrically insulative and flexible, such as an elastomer or other very soft material preferably with a tensile strength of 1000 psi or lower. The interface layer 3501 may be formed using a mold derived from a scan of a circuit board.

The EMI shielding layer, or protective layer, 3502 may be produced using the technique described herein and may be fabricated of a polymer with an EMI shielding additive, or may be a polymer coated or plated with an EMI shielding material, such as Copper, Nickel, Tin, Gold, Chrome or conductive point. It may be advantageous, in some applications, to use a material with a EMI shielding coating, because materials with fillers may behave unexpectedly after being formed, or after any heating step in the manufacturing process. As used here, polymer layer may be a thermally formed polymer layer, an injection molded plastic layer, or 3d printed polymer layer. An EMI shielding layer 3502 could also potentially be made from a thin sheet of metal, e.g. Copper or Aluminum, or other metal which would produce an EMI shielding effect, but such a layer of metal, formed by itself, would need to be much thicker, due to forming considerations, than what would should be required for EMI shielding.

The bottom surface of the second layer may be formed using the scan data, but with an offset included to account for the thickness of the first layer 3501. As will be described, the top surface of the second layer 3502 may be formed using the scan data but with the height adjusted to the height of the thermal management caps 3606 to present a uniform surface.

FIG. 38 is top perspective view of an example case of a protective layer 3502 having cutouts to accommodate thermal management caps and to provide a uniform surface for a thermal management layer 3503. The first layer 3501 and the second layer 3502 comprise cutouts 3701, 3703 corresponding to the top of the electrical components 103 which are to be thermally managed, to allow good transfer of thermal energy between the thermal management layer 3503 and the components.

A thermal shielding cap 3606 may be formed, corresponding to the shape of the electronic component 103 and of a material with good thermally conductive properties, such as copper. The cutout/cap method is advantageous for a thermal management because of the importance of good physical contact between the thermal management cap 3606 and the electrical component 103 to be thermally managed. This is because the thermal management cap 3606 may be placed directly on top of the electrical component 103 before the thermal management cap 3606 is sealed to the thermal management layer 3503, which would mitigate any minute gaps between them that may have existed as a result of tolerances in the height of the electrical component 103.

In this embodiment, thermally conductive material 3604, such as thermal paste has been included to improve the transfer of thermal energy between the electrical components 103 and the thermal cap 3606.

The top surface of the second layer 3502 may be formed using the scan data but with the height adjusted to the height of the thermal management caps 3606 thereby creating a uniform surface height of the assembly.

After the layers and thermally conductive cap 3606 have been put in place, joining procedures may be used such as the use of EMI shielding paste along the border where the second layer 3502 and the thermal management cap 3606 meet.

A thermal management layer 3503 is placed directly on top of the uniform surface created by the top surface of the thermal management cap 3606 and the top surface of the second layer 3502. In an embodiment, the thermal management layer does not extend beyond the area of the surface with uniform height. The thermal management layer 3503 may be formed of a high thermal conductivity artifact such as graphite sheets and/or may comprise thermal management elements such as a vapor chamber or a heat sink.

A second approach to provide a uniform surface height involves the addition of a cover layer preceding the thermal management layer 3503. FIG. 39 is an exploded illustration of an example embodiment where a cover layer provides a uniform surface for a thermal management layer 3503.

A populated circuit board 111 with at least one electronic component 103 is covered by at least one protective layer 3502 and a thermal management layer 3503. In between the protective layer 3502 and the thermal management layer 3503 is a cover layer 3901 for providing a uniform surface for the thermal management layer 3503. In the embodiment shown, the populated circuit board is covered by a first layer 3501 which may be an interface layer 3501, a second layer 3502 which may be, but is not limited to, an EMI shielding layer 3502 and the cover layer 3901.

In an embodiment, the interface layer 3501 is both electrically insulative and flexible, such as an elastomer or other very soft material preferably with a tensile strength of 1000 psi or lower. The interface layer 3501 may be formed using a mold derived from a scan of a circuit board.

FIG. 40 is a top perspective view of an exploded layer assembly showing a protective layer and a cover layer.

FIG. 41 is top perspective view showing an assembled protective layer and cover layer. The EMI shielding layer 3502 may be produced using the technique described herein and may be fabricated of a polymer with an EMI shielding additive, or may be a polymer coated or plated with an EMI shielding material, such as Copper, Nickel, Tin, Gold, Chrome or conductive point. It may be advantageous, in some applications, to use a material with a EMI shielding coating, because materials with fillers may behave unexpectedly after being formed, or after any heating step in the manufacturing process. As used here, polymer layer may be a thermally formed polymer layer, an injection molded plastic layer, or 3d printed polymer layer. An EMI shielding layer 3502 could also potentially be made from a thin sheet of metal, e.g. Copper or Aluminum, or other metal which would produce an EMI shielding effect, but such a layer of metal, formed by itself, would need to be much thicker, due to forming considerations, than what would should be required for EMI shielding.

The second layer 3502 may be formed using the scan data, but with an offset included to account for the thickness of the first layer 3501.

The interface layer 3501 and the EMI shielding layer 3502 comprise cutouts 3701, 3703 corresponding to the top of the electrical components 103 which are to be thermally managed, to allow good transfer of thermal energy between the thermal management layer 3503 and the components 103.

A thermal management cap 3606 may be formed, corresponding to the shape of the electronic component 103 and of a material with good thermally conductive properties, such as copper. The cutout/cap method is advantageous for a thermal management because of the importance of good physical contact between the thermal management cap 3606 and the electrical component 103 to be thermally managed. This is because the thermal management cap 3606 may be placed directly on top of the electrical component 103 before the thermal management cap 3606 is sealed to the thermal management layer 3503, which would mitigate any minute gaps between them that may have existed as a result of tolerances in the height of the electrical component 103.

In this embodiment, thermally conductive material 3604, such as thermal paste has been included to improve the transfer of thermal energy between the electrical components 103 and the thermal management cap 3606.

The cover layer 3901 comprises a top surface which is a uniform height and the same height as the thermal management caps 3606. This allows a flat thermal management layer 3503 to be placed on top of the cover layer 3901. The cover layer 3901 further comprises cutouts 3903 corresponding to the top of the electrical components 103 which are to be thermally managed and sized and dimensioned to receive the thermal management cap 3606, to allow good transfer of thermal energy between the thermal management layer 3503 and the components 103.

The cover layer 3901 comprises a plurality of support legs 3905 extending from the bottom surface of the cover layer toward the shielding layer 3502 to provide an offset for the bottom surface of the cover layer 3901 such that when the cover layer 3901 is placed on top of the second layer 3502, the bottom surface of the cover layer 3901 does not interfere with the varying height of the second layer 3502.

After the layers and thermal management cap 3606 have been put in place, joining procedures may be used such as the use of EMI shielding paste along the border where the cover layer 3901 meets the second layer 3502 and the thermal management cap 3606.

A thermal management layer 3503 is placed directly on top of the uniform surface created by the top surface of the thermally conductive cap 3606 and the top surface of the cover layer 3901. The thermal management layer 3503 may be formed of a high thermal conductivity artifact such as graphite sheets and/or may comprise thermal management elements such as a vapor chamber or a heat sink.

It is an objective of the invention to create conformal or soft molds that are actually thermally conductive to soften thermoplastic layer material quickly. Using gentle heat from inside the soft mold 2700, the polymer layer materials are kept in the softened state until pressure from the mold completes the forming or net-shape. Air cooling, or cooling systems inside the forming machine, lower part temperatures to “freeze” the part so it can be handled and used immediately.

Exemplary mold heaters include for example, a silicone pad type while cartridge heaters, wire networks, ceramic elements and piped fluids are alternate heating methods.

To create heat transfer from the heating elements inside the conformal mold 3300 to the polymer layers, a thermally conductive mold material was developed. Thermally conductive fillers 3320 can be added to the silicone or elastomer mold materials while keeping the molds at Shore A durometers that range from 60-80. The fillers 3320 are small in size so the mold 3300 does not become too rigid and loose the conformal qualities.

Exemplary fillers include aluminum powder, copper platelets, alumina and boron particles, ceramic whiskers, metal-plated graphite fibers, tungsten fibers, and carbon black. Various ratios of filler to mold resin could be used, depending on the circuit board assembly 100.

The following exemplary filler composition using aluminum fillers to make the compliant molds 3300 resulted in the following:

15% filler provided minimal heat transfer;

25% filler provided 20-40% heat transfer;

37% filler provided 45-60% heat transfer; and

50% filler provided 65-75% heat transfer.

The compliant molds 2800 and 3300 allow a uniform thickness and consistent quality of polymer layers 1100 to be applied to the surface of the circuit board assembly 100 with complex and imprecise geometries. They also provide the numerous advantages among which are the following:

The compliant face 2700 of the mold 2800 enables forces in the X (left and right) and Y (front and back) directions, in addition to the Z (up and down) or the directions perpendicular to the draw.

The interface pressures between the compliant face 2700 and surfaces of all the components are substantially consistent.

The compliant face 2700 of the mold 2800 will adapt to the shape of the electronic components when it is pressed against the circuit board assembly 100 and the polymer layers 1100, and even allows the forming of polymers to minor undercuts;

The compliant face of the mold 2800 reduces the need for heavy draft used to release the encapsulated circuit board assembly 100 from the molding tool.

The compliant material of the mold 2800 can be cast with internal air channels or voids that enable the soft mold face 2700 to expand, to accommodate additional deformation, and to and stretch for compliant molding of intricate geometries and geometries with a high depth-to-draw ratio.

The processes of forming the polymer layers according to the present invention can be done using a combination of films (sometimes called cap stock) in a laminate or one layer formed on top of another. Multiple polymer layers can be designed to solve a variety of load and harsh environmental problems. The following examples are provided for illustration purpose:

Example A: Polymer Layer with EMC (Electro Mechanical Compatibility) Protection

The present process is suited to form a non-conductive layer followed by an electrically conductive layer to shield the circuit board assembly 100 against unintended electrical transmission or infiltration. The electrically conductive or shielding layer may utilize nickel plated fibers, metallic fibers, conductive veils or cloth, electro less nickel plating of the thermoplastic layer or vacuum deposition of metal particles on the polymer layer.

Example B: Insulative Polymer Layers

A protective barrier for extreme cold is readily accomplished using the present invention. First, a non-conductive layer is formed, followed by a “foamed” layer or a layer that has a cellular structure. The air bubbles or cells from the density reduction act as an effective insulator. Wires or pads internal to the polymer layers can function as instant heaters for cold start-up. Reference is made to FIG. 33.

Example C: Heat Extractor Polymer Layers

Plastics offer very little conduction of heat. So many circuit board assemblies rely on metal surfaces to conduct and then radiate_heat away from electrical and electronic components while other assemblies use mechanical movement of air or forced convection. There will be cases where the polymer layers will be formed (or molded) with air channels and/or wicking structures for heat pipes or heat extractors. Metal pads over components serve as thermal pick-ups which then pipe the heat outside of the enclosed area or to outside air.

The following is a non-exclusive list of exemplary polymers that can be used to form the thermoplastic sheets or layers: polycarbonate, polyethylene, siloxane rubber, alloy grade with added styrene, polyolefin materials, low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, metalocene based polyethylene, polyvinyl chloride, and high impact polystyrene.

It should be understood that other modifications may be made to the present embodiments without departing from the spirit and scope of the invention. 

The invention claimed is:
 1. A method for encapsulating a populated circuit board assembly having an imprecise geometry, with at least one protective layer that is tightly fit to the imprecise geometry of the populated circuit board assembly, the method comprising: wherein said populated circuit board assembly includes at least one circuit board component, which has a footprint area associated with it, which corresponds to the area on the populated circuit board assembly under a space occupied by said circuit board component; modeling the at least one protective layer of the populated circuit board assembly; using the model to encapsulate the populated circuit board assembly with said at least one protective layer; wherein modeling the at least one protective layer includes: scanning the populated circuit board assembly to create a surface file of the populated circuit board assembly; wherein said populated circuit board assembly includes at least one circuit board component of a component type, for which component type, the physical features, and dimensional tolerances of said circuit board component are known; modifying the surface file to allow dimensional tolerances of said component type; modifying the surface file to allow space for a thermally conductive cap for each at least one circuit board component, wherein each thermally conductive cap is a uniform height modifying the surface file such that a top surface of the surface file covering the footprint area of all circuit board components is at a uniform height; wherein encapsulating the populated circuit board assembly with said at least one protective layer includes: using the modified surface file to form an envelope with a substantially precise representation of the populated circuit board assembly with at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component; placing a thermally conductive cap for each at least one circuit board component on said circuit board component; and placing the formed envelope with cutout onto the populated circuit board, such that said cutout on the envelope allows said thermal cap to be left uncovered by said formed envelope with cutout.
 2. The method of claim 1 further comprising placing a thermally conductive layer over the flat surface of the envelope.
 3. The method of claim 2 wherein a thermal interface between said thermally conductive cap and said thermally conductive layer is sealed together using a thermally conductive material.
 4. The method of claim 2 further comprising the step of providing a heat exchanger in communication with the thermally conductive layer.
 5. The method of claim 1 wherein the step of using the modified surface file to form an envelope with a substantially precise representation of the populated circuit board assembly with at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component further comprises modifying the surface file to at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component.
 6. The method of claim 1 wherein the step of using the modified surface file to form an envelope with a substantially precise representation of the populated circuit board assembly with at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component further comprises creating at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component.
 7. The method of claim 1 wherein the step of using the modified surface file to form an envelope with a substantially precise representation of the populated circuit board assembly with at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component further comprises using the modified surface file to additively manufacture the envelope.
 8. The method of claim 1 wherein: the step of using the modified surface file to form an envelope with a substantially precise representation of the populated circuit board assembly with at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component further comprises: using the modified surface file to create a mold; heating a first protective layer of said at least one protective layer; drawing the heated first protected layer over and past the positive mold, in order to form an envelope with a substantially precise representation of the populated circuit board assembly; releasing the envelope from the positive mold; creating at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component to form a formed envelope with the cutout.
 9. A method for encapsulating a populated circuit board assembly having an imprecise geometry, with at least one protective layer that is tightly fit to the imprecise geometry of the populated circuit board assembly, the method comprising: wherein said populated circuit board assembly includes at least one circuit board component, which has a footprint area associated with it, which corresponds to the area on the populated circuit board assembly under a space occupied by said circuit board component; creating a model of the at least one protective layer of the populated circuit board assembly; using the model to encapsulate the populated circuit board assembly with said at least one protective layer; placing an interface layer over the at least one protective layer, the interface layer comprising a top surface having a uniform height, a bottom surface in communication with a top surface of the protective layer and for each circuit board component a cutout which corresponds to the footprint area of the at least one circuit board component; wherein modeling the at least one protective layer includes: scanning the populated circuit board assembly to create a surface file of the populated circuit board assembly; wherein said populated circuit board assembly includes at least one circuit board component of a component type, for which component type, the physical features, and dimensional tolerances of said circuit board component are known; modifying the surface file to allow dimensional tolerances of said component type; modifying the surface file to allow space for a thermally conductive cap for each at least one circuit board component, wherein each thermally conductive cap is a uniform height; wherein encapsulating the populated circuit board assembly with said at least one protective layer includes: using the modified surface file to form an envelope with a substantially precise representation of the populated circuit board assembly with at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component; placing a thermally conductive cap for each at least one circuit board component on said circuit board component; and placing the formed envelope with cutout onto the populated circuit board, such that said cutout on the envelope allows said thermal cap to be left uncovered by said formed envelope with cutout.
 10. The method of claim 9 further comprising placing a thermally conductive layer over the top surface of the interface layer having a uniform height.
 11. The method of claim 10 wherein a thermal interface between said thermally conductive cap and said thermally conductive layer is sealed together using a thermally conductive material.
 12. The method of claim 10 further comprising the step of providing a heat exchanger in communication with the thermally conductive layer.
 13. The method of claim 9 wherein the step of using the modified surface file to form an envelope with a substantially precise representation of the populated circuit board assembly with at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component further comprises modifying the surface file to at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component.
 14. The method of claim 9 wherein the step of using the modified surface file to form an envelope with a substantially precise representation of the populated circuit board assembly with at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component further comprises creating at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component.
 15. The method of claim 9 wherein the step of using the modified surface file to form an envelope with a substantially precise representation of the populated circuit board assembly with at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component further comprises using the modified surface file to additively manufacture the envelope.
 16. The method of claim 9 wherein: the step of using the modified surface file to form an envelope with a substantially precise representation of the populated circuit board assembly with at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component further comprises: using the modified surface file to create a mold; heating a first protective layer of said at least one protective layer; drawing the heated first protected layer over and past the positive mold, in order to form an envelope with a substantially precise representation of the populated circuit board assembly; releasing the envelope from the positive mold; creating at least one cutout on the envelope, which corresponds to the footprint area of the at least one circuit board component to form a formed envelope with the cutout. 